Flocked Helical Spring Coating for Stronger Fiber Adhesion
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Solution Overview
Problem
The existing flocked springs face issues with adhesive peeling off due to smooth cationic electrodeposition coatings, leading to reduced sound-reduction effectiveness and durability, as the adhesive required for fixing short fibers easily detaches, causing the fibers to fall off.
Innovation Solution
A flocked spring design featuring a cationic electrodeposition coating layer with an adhesive layer and a flocking layer, where the surface roughness of the cationic electrodeposition coating layer is 19.6 μm or more, utilizing an adhesive with a surface roughening solvent to enhance adhesion and prevent peeling, and a baking process to secure the flocking filler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cationic electrodeposition coating is applied to the spring surface to achieve anti-rust resistance and smooth finish, then anti-rust performance is improved, but the adhesive layer easily peels off due to the smooth surface
Solution Approach 1:
The invention changes the surface parameter of the electrodeposition coating by controlling the surface roughness (Rz) to be 19.6 μm or more. This parameter change transforms the smooth surface into a rough surface that provides mechanical interlocking for the adhesive layer, thereby improving adhesive bonding strength while maintaining the anti-rust properties of the electrodeposition coating.
2Strength
If the surface roughness is increased to improve adhesive bonding, then adhesive peeling is prevented, but the coating process becomes more complex
Solution Approach 1:
The invention merges the electrodeposition coating process with the adhesive application process by specifying that the adhesive is applied directly to the electrodeposition coating surface without requiring separate surface treatment steps. The rough surface morphology is achieved through the electrodeposition process itself, combining coating formation and adhesive bonding preparation into one integrated process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The increased surface roughness of the cationic electrodeposition coating layer enhances the adhesion force between the coating and adhesive layers, preventing peeling and maintaining sound reduction effectiveness while reducing manufacturing costs and time.
Implementation Method 1
a cationic electrodeposition coating process of performing a cationic electrodeposition coating treatment on the spring body, to form a coating film of electrodeposition coating material on the surface of the spring body
Implementation Method 2
an adhesive coating process of coating the adhesive having a surface roughening solvent on the surface of the coating film
Implementation Method 3
an adhesive layer provided on a surface of the cationic electrodeposition coating layer, and a flocking layer composed of a flocking filler that is fixed to the adhesive layer
Implementation Method 4
a baking process of heating the spring body adhered with the flocking filler
Data Source
AI summary
The flocked helical spring includes a spring body, a cationic electrodeposition coating layer disposed on the surface of the spring body, an adhesive layer disposed on the surface of the cationic electrodeposition coating layer, and a flocking layer composed of flocking fillers fixed to the adhesive layer. The surface roughness Rz of the cationic electrodeposition coating layer is 19.6 μm or greater. The method for producing a flocked helical spring includes a cationic electrodeposition coating process of performing a cationic electrodeposition coating treatment on a spring body to form a film of an electrodeposition coating material on the surface of the spring body; an adhesive coating process of coating an adhesive containing a surface roughening solvent on the surface of the film; a flocking process of bonding flocking fillers to the surface coated with the adhesive; and a baking process of heating the spring body adhered with the flocking fillers.